Multi-layer wearable body armor

ABSTRACT

A multi-layer body armor plate includes a strike plate; a mesh layer positioned over the strike plate, the mesh layer having a number of open cells; and an outer skin layer positioned over the mesh layer so as to encapsulate the open cells of the mesh layer between the strike plate and the outer skin layer. The open cells of the mesh layer may entrap air or may be filled with expandable, buoyant foam.

RELATED APPLICATION

This is a continuation-in-part application of continuation U.S.application Ser. No. 16/687,969, filed Nov. 19, 2019, entitledMULTI-LAYER WEARABLE BODY ARMOR, which claims priority to U.S.application Ser. No. 16/208,676, filed Dec. 4, 2018, entitledMULTI-LAYER WEARABLE BODY ARMOR, which is now U.S. Pat. No. 10,591,257,issued Mar. 17, 2020 and both of which are hereby incorporated byreference into the present application in their entirety.

STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with Government support under Contract No.:DE-NA0002839 awarded by the United States Department of Energy/NationalNuclear Security Administration. The Government has certain rights inthe invention.

BACKGROUND

The present invention relates to body armor for protecting wearers frombullets and other ballistic projectiles.

Conventional body armor typically includes ceramic or steel platesembedded in vests or other articles of clothing. Although effective inmany applications, ceramic and steel body armor plates suffer fromlimitations that limit their utility. For example, ceramic body armorplates are relatively thick and therefore limit wearers' mobility andability to quickly reach firearms, radios, and other equipment. Ceramicbody armor plates are also expensive and cannot be easily sized andshaped to conform to a particular wearer's physique. Ceramic body armorplates are also brittle and often crack when struck by projectiles. Suchcracking makes them less effective at protecting against subsequentprojectile strikes in the same area.

Steel body armor plates are often thinner than ceramic plates andtypically don't crack as easily. But steel plates are heavy andtherefore limit their wearers' mobility. And, as with ceramic plates,steel body armor plates are not easily sized and shaped to conform to aparticular wearer's physique. Steel body armor plates also sometimescause secondary injuries when projectiles fragment and “splash” off themand strike their wearers or others nearby. Another problem with bothceramic and steel body armor plates is they are so negatively buoyantthat they can't be safely used in body armor that may be worn in or neardeep bodies of water.

SUMMARY

The present invention solves the above-described problems and otherproblems with conventional body armor by providing a multi-layer bodyarmor plate that is thinner and lighter than ceramic or steel body armorplates, more effective against projectile fragmentation, capable ofwithstanding multiple projectile hits, more easily sized and shaped toconform to a particular wearer's physique, and less negatively buoyantand therefore safer to wear in or near bodies of water.

A body armor plate constructed in accordance with an embodiment of theinvention broadly comprises a strike plate; a mesh layer positioned overthe strike plate; and an outer skin layer positioned over the meshlayer. The strike plate is worn closest to a wearer's torso or otherbody part. The mesh layer covers the outer face of the strike plate andhas repeating and intersecting walls that define a number of open cells.The outer skin layer covers the mesh layer and encapsulates the opencells in the mesh layer.

The layers of the body armor plate cooperate to arrest projectilefragments and reduce injuries from fragmentation. Specifically, when aprojectile strikes the body armor plate, it first penetrates, but isslowed by, the outer skin layer and the mesh layer. When it strikes thestrike plate, it may fragment, but the fragments are slowed by andtrapped within the mesh layer. This prevents the fragments fromsplashing off the body armor plate and injuring the wearer and/or othersnearby.

The mesh layer, and particularly the trapped air in the mesh layer,reduce the negative buoyancy of the body armor plate so that it is saferto wear in or near bodies of water than steel or ceramic plates. Thebody armor plate is also lighter than ceramic or solid metal body armorplates.

In one embodiment, the strike plate is formed of a metal matrixcomposite material using additive manufacturing techniques. The meshlayer and outer skin layer may also be co-formed with the strike platevia the same additive manufacturing process or may be formed separatelyand adhered to the strike plate. Forming some or all of the layers ofthe body armor via additive manufacturing permits the body armor to besized and shaped to conform to a particular wearer's physique. Moreover,additive manufacturing permits the thicknesses of the strike plate andother layers to be selected to provide protection against differenttypes and speeds of ballistic projectiles.

An embodiment of the metal matrix composite material comprises a metalmatrix and nanocellulose supplement. Use of such a metal matrixcomposite material allows the layers of the body armor plate to berelatively thin and lightweight while still providing sufficientprotection against projectiles. This material also resists cracking andthus protects against multiple ballistic strikes in the same area.

Some embodiments of the body armor plate may also include an expandable,buoyant foam that at least partially fills the open cells of the meshlayer. In other embodiments, the open cells simply trap air inside thebody armor plate.

Embodiments of the invention may also include a vest or other wearablearticle of clothing in which one or more of the above-described bodyarmor plates may be supported over a wearer's torso or other body part.The body armor plates may also be applied to or embedded within otherobjects such as vehicle door panels, walls, ceilings, etc.

This summary is provided to introduce a selection of concepts in asimplified form that are further described in the detailed descriptionbelow. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter. Other aspectsand advantages of the present invention will be apparent from thefollowing detailed description of the embodiments and the accompanyingdrawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the present invention are described in detail below withreference to the attached drawing figures, wherein:

FIG. 1 is a partial vertical cross-sectional view of a body armor plateconstructed in accordance with an embodiment of the present invention.

FIG. 2 is a front elevational view of the body armor plate of FIG. 1with portions hidden to reveal interior features.

FIG. 3 is a flow diagram depicting steps in a method of making acomposite material that may be used to fabricate the body armor plate.

FIG. 4 is a flow diagram depicting steps in a method of fabricating thebody armor plate via an additive manufacturing process.

FIG. 5 is a partial vertical cross-sectional view of a body armor plateconstructed in accordance with another embodiment of the presentinvention.

FIG. 6 is a back elevational view of the body armor plate of FIG. 5 withportions hidden to reveal interior features.

FIG. 7 is a flow diagram depicting steps in a method of fabricating thebody armor plate via an additive manufacturing process.

The drawing figures do not limit the present invention to the specificembodiments disclosed and described herein. The drawings are notnecessarily to scale, emphasis instead being placed upon clearlyillustrating the principles of the invention.

DETAILED DESCRIPTION

Embodiments of the present invention provide a body armor plate formedof multiple layers that are cooperatively configured so as to be thinnerand lighter than ceramic or steel body armor plates, more effectiveagainst projectile fragmentation, capable of withstanding multipleprojectile hits, and less negatively buoyant and therefore safer to wearin or near bodies of water. Some or all of the layers of the body armorplate may be formed via additive manufacturing techniques so that thebody armor plate may be more easily sized and shaped to conform to aparticular wearer's physique. The plates are preferably formed of ametal matrix composite material that is stronger and lighter than manyconventional materials.

Specific embodiments of the body armor plate will now be described withreference to the attached drawing figures. Turning now to FIGS. 1 & 2 ,a body armor plate 10 constructed in accordance with embodiments of theinvention is illustrated and broadly comprises a strike plate 12; a meshlayer 14 positioned over the strike plate 12; and an outer skin layer 16positioned over the mesh layer 14. Each of these layers are described inmore detail below.

Some embodiments of the body armor plate may also comprise expandable,buoyant foam 18 that at least partially fills voids in the mesh layer.In other embodiments, the voids in the mesh layer are filled withentrapped air instead.

The strike plate 12 has an inner face 20 for at least partially coveringthe wearer's chest, back, or other body portion and an outer strike face22 that may be impacted by a ballistic projectile. As shown in FIG. 2 ,concave reliefs 24, 26 may be formed in the upper corners of the strikeplate 12 for accommodating the wearer's arms. Similar concave reliefs28, 30 may be formed in the lower corners of the strike plate 12 foraccommodating the wearer's hips and thighs. In one embodiment, thestrike plate has a multi-curved profile for conforming to the wearer'storso. Specifically, the strike plate may be curved from top-to bottomand from side-to-side so as to closely conform to a wearer's chestand/or abdomen. The strike plate 12 may be formed in any thickness, andin one embodiment, is between 0.125 and 0.5 inches thick.

The strike plate 12 is preferably formed of a metal matrix compositematerial comprising a metal matrix and a nanocellulose supplement. Themetal matrix forms a base structure and may be a monolithic materialsuch that the metal matrix is continuous throughout the compositematerial. The metal matrix may be formed of aluminum, magnesium,titanium, or other structural metals, or cobalt, cobalt-nickel alloys,steel and ferrous alloys, or other metals for high-temperatureapplications. The metal matrix may be formed from a metal base materialsuch as a powder or feedstock.

The nanocellulose supplement improves properties of the compositematerial and may be microscopic nanocellulose particles dispersedthroughout the metal matrix. The nanocellulose supplement may besubstantially mixed with particles of the metal matrix such that thecomposite material is a homogenous composite. The nanocellulosesupplement may be any form of nano-structured cellulose. This may beeither cellulose nanofibers (CNF), also called microfibrillatedcellulose (MFC), nanocrystalline cellulose (NCC), also calledcrystalline nanocellulose, and bacterial nanocellulose, which refers tonano-structured cellulose produced by bacteria, among others, not tolimit other potential forms or sources of nanocellulose. Thenanocellulose supplement may increase the strength, change porosity ofthe metal matrix, or alter other properties of the composite material10. The nanocellulose supplement may be formed from a nanocellulosesupplement material.

Use of such a metal matrix composite material allows the strike plate 12(and other layers of the body armor plate 10 if formed from the samematerials) to be relatively thin and lightweight while still providingsufficient protection against projectiles. This material also resistscracking and thus provides all or much of its initial protection evenwhen subjected to multiple ballistic strikes in the same area. Theabove-described metal matrix composite material may be used to form thestrike plate and/or other layers of the body armor plate 10 via anadditive manufacturing process described below.

The mesh layer 14 is positioned over the strike plate 12 and has aninner side 32 positioned on the outer strike face of the strike plate 12and an opposite outer side 34. The mesh layer may include the sameconcave reliefs and multi-curved profile as the strike plate 12 so as tomatch the overall shape and size of the strike plate. The mesh layer mayhave any thickness, and in one embodiment, is approximately the samethickness as the strike plate 12, between 0.125 and 0.5 inches thick.

As best shown in FIG. 2 , the mesh layer 14 also has a number ofintersecting walls 36 that define a plurality of open cells 38 betweenits inner and outer sides 32, 34. The walls 36 and cells 38 may be in ahoneycomb pattern, grid pattern, or any other repeating or non-repeatingpattern. Any number of cells 38 of any size may be formed in the meshlayer. In one embodiment, the mesh layer has a cell density ofapproximately 12 cells per square inch, and each cell has a volume ofapproximately 0.015 cubic inches.

As illustrated in FIGS. 1 & 2 , the mesh layer may also have accessholes 40 along one or more of its edges through which excess powder maydrain after an additive manufacturing process has been completed. Inembodiments which include expandable foam, these access holes may alsobe used to inject the expandable foam as described in more detail below.

The mesh layer may 14 be co-formed with the strike plate 12 via the sameadditive manufacturing process or may be formed separately and adheredto the strike plate with adhesives or fasteners. Similarly, the meshlayer may be formed of the same metal matrix composite material as thestrike plate or a different material.

The outer skin layer 16 is positioned over the mesh layer 14 and has aninner face 42 and an opposite outer face 44. The outer skin layer 16 maywrap around the edges of the mesh layer 14 so that its inner face 42encapsulates the open cells 38 of the mesh layer 14 between it and thestrike plate 12. The outer skin layer 16 may have any thickness, and inone embodiment, is between 0.025 and 0.0625 inches thick.

The outer skin layer 16 may be co-formed with the strike plate 12 viathe same additive manufacturing process or may be formed separately andadhered to the strike plate. Likewise, the outer skin layer 16 may beformed of the same metal matrix composite material as the strike plateor a different material.

The open cells 38 in the mesh layer 14 entrap air. In other embodiments,foam 18 at least partially fills the open cells 38 in the mesh layer 14.The entrapped air or foam protect against fragmentation. The foam 18 maybe any expandable material. In one embodiment, the foam is injected intothe open cells 38 of the mesh layer 14 via the access holes 40. In otherembodiments, the foam 18 is added to the mesh layer 14 as the mesh layeris fabricated.

Embodiments of the invention may also include a vest or other wearablearticle of clothing for supporting one or more of the above-describedbody armor plates 10 over a wearer's torso or other body part. The bodyarmor plates 10 may also be applied to or embedded within objects suchas vehicle door panels, walls, ceilings, etc.

The above-described body armor plate 10 provides numerous advantages.For example, the layers 12, 14, 16 cooperate to arrest projectilefragments and reduce related injuries. When a projectile strikes thebody armor plate 10, it penetrates, but is slowed by, the outer skinlayer 16 and the mesh layer 14. When it strikes the strike plate 12, itmay fragment, but the fragments are slowed by and trapped within themesh layer 14. This protects the wearer and those nearby fromfragmentation. The mesh layer 14, and the trapped air or foam in themesh layer also improve the negative buoyancy of the body armor plate10.

Methods of forming the metal matrix material used in the body armorplate 10 and fabricating the body armor plate itself are depicted in theflow charts of FIGS. 3 & 4 . These flow charts show some of the aspectsof preferred implementations of the present invention. In somealternative implementations, the steps or functions noted in the variousblocks may occur out of the order depicted in the figures. For example,two blocks shown in succession may in fact be performed substantiallyconcurrently, or the steps may be executed in the reverse order or adifferent order.

Exemplary methods for forming the metal matrix materials will now bedescribed with reference to FIG. 3 . To form the composite material viaconsolidation such as additive manufacturing, casting, and sintering, ametal base material (e.g., microscopic metal matrix particles) such asmetal powder and a nanocellulose supplement material (e.g., microscopicnanocellulose particles) may be blended together such that thenanocellulose supplement material is dispersed in the metal basematerial as shown in block 100 of FIG. 3 . This may be performed viapre-mixing, simultaneous material dispensing, or any other suitabledispersion.

The metal base material and the nanocellulose supplement material maythen be consolidated such as via high temperature consolidation (e.g.,compaction, degassing, and/or thermo-mechanical treatment) such that themetal base material fuses or otherwise bonds together with thenanocellulose supplement material being dispersed throughout the metalmatrix, as shown in block 102. The nanocellulose supplement material maybe heated to a predetermined temperature and/or pressure for apredetermined amount of time for effecting proper fusing of the metalbase material and dispersion of the nanocellulose supplement material.The consolidation may also be performed in a vacuum or under pressure.

The nanocellulose supplement material may be subjected to partialburnout or complete burnout such that at least some of the organicstructure of the nanocellulose supplement material 18 is reduced tocarbon, as shown in block 104. This results in undamaged carbonreinforcing the metal matrix.

The composite material may also be formed via electroplating,electroforming, vapor deposition, and in-situ fabrication. For example,the metal matrix and the nanocellulose supplement may be blended viasolid state, semi-solid state, or liquid state processing. Theparticular nanocellulose supplement material may be selected accordingto the desired improved property of the composite material. The relativepercentage of nanocellulose supplement to metal matrix may also bechosen according to the desired properties of the composite material.For example, more nanocellulose supplement may be used if additionalstrength is desired.

The above-described composite material and method of forming the sameprovide several advantages over conventional composite materials. Forexample, the nanocellulose supplement material 18 can be dispersed inthe metal base material without damage to the nanocellulose supplementmaterial, unlike graphene and carbon nanotubes which become damagedduring formation. The nanocellulose supplement material is also moreeasily dispersed in the metal base material than graphene and carbonnanotubes. The composite material 10 can be formed via additivemanufacturing, casting, and sintering, allowing for the compositematerial to be used in large and small structural, electrical,biochemical, and biomechanical applications. Nanocellulose is also arenewable and readily available resource.

Exemplary methods of forming body armor plates such as the body armorplate 10 described above will now be described with reference to FIG. 4. In one embodiment, the body armor plates are fabricated with powderbed fusion additive manufacturing techniques comprising the followingsteps. First, the strike plate 12 is formed by depositing a metal matrixcomposite material onto a form or other structure as shown in block 200.The strike plate 12 may be formed so as to have a multi-curved profile,an inner face 20, an outer strike face 22, upper corner concave reliefs24, 26, and lower corner concave reliefs 28, 30 as shown in FIG. 2 .This step may comprise or be proceeded by the step of designing theshape and multi-curved profile of the strike plate 12 so it conforms toa particular wearer's torso or other body part.

Next, the mesh layer 14 is formed by depositing additional metal matrixcomposite material on the strike plate 12 as shown in block 202.Alternatively, the mesh layer 14 may be formed separately from thestrike plate 12 and subsequently glued or otherwise attached to thestrike plate. The mesh layer 14 may be formed so as to have an innerside 32 positioned on the outer strike face 22 of the strike plate 12and an opposite outer side 34. The mesh layer also includes a number ofintersecting walls 36 that define a number of open cells 38. The accessholes 40 in the mesh layer 14 may also be formed in this step.

Next, the outer skin layer 16 is formed by depositing additional metalmatrix composite material on the mesh layer 14 as shown in block 204.Alternatively, the outer skin layer 16 may be formed separately andglued on otherwise attached over the mesh layer 14. The outer skin layer16 is preferably formed so as to extend over the edges of the mesh layer14 to encapsulate the mesh layer 14 between the strike plate 12 and theouter skin layer 16.

During the formation of the layers 12, 14, 16, any unfused metal matrixpowder may drain from the body armor plate via the access holes 40.

In embodiments of the body armor plate that include foam in the meshlayer 14 rather than entrapped air, expandable, buoyant, closed cellfoam 18 is injected in the open cells 38 of the mesh layer 14 asdepicted in block 206. In some embodiments, other materials such asepoxies or polymers may be used instead of foam, and as mentioned above,in some embodiments, only air or other gas is trapped in the open cells38. The foam or other materials may be injected into the open cells viathe access holes 40. The access holes are then sealed with any suitablematerials as depicted in block 208.

Finally, one or more of the fabricated body armor plates 10 is insertedin a vest or other wearable item as depicted in block 210. The plates 10may also be inserted in or attached to walls, door panels, and otherstructures or objects.

Forming some or all of the layers of the body armor plate 10 viaadditive manufacturing as described above permits the body armor platesto be sized and shaped to conform to a particular wearer's physique.Moreover, additive manufacturing permits the thicknesses of the strikeplate 12 and other layers to be selected to provide protection againstdifferent types and speeds of ballistic projectiles. Different portionsof each layer can also be formed in different thickness to provide extraprotection or extra mobility as needed. For example, portions of thelayers 12, 14, 16 configured to cover a wearer's heart maybe relativelythicker for added protection whereas portions of the layers configuredto cover a wearer's hips may be relatively thinner to provide bettermobility.

Turning now to FIGS. 5 and 6 , a body armor plate 10A constructed inaccordance with another embodiment of the invention is illustrated. Thecomponents of body armor plate 10A that correspond to similar componentsin body plate armor 10 have an ‘A’ appended to their reference numerals.The body plate armor 10A may comprise substantially similar componentsas body plate armor 10, except that it further includes an inner meshlayer 15A and an inner skin layer 16A.

The inner mesh layer 15A may be substantially similar to mesh layer 14A,or outer mesh layer 14A, except that inner mesh layer 15A is positionedon the inner face 20A of the strike plate 12A. The inner mesh layer 15Amay include the same concave reliefs and multi-curved profile as thestrike plate 12A so as to match the overall shape and size of the strikeplate 12A. The inner mesh layer 15A may have any thickness, and in oneembodiment, is approximately the same thickness as the strike plate 12A,between 0.125 and 0.5 inches thick. The inner mesh layer 15A ispositioned adjacent the strike plate 12A and has an outer side 33Apositioned on the inner face 20A of the strike plate 12A and an oppositeinner side 35A. The inner mesh layer may 15A include the same concavereliefs and multi-curved profile as the strike plate 12A so as to matchthe overall shape and size of the strike plate. The inner mesh layer 15Amay have any thickness, and in one embodiment, is approximately the samethickness as the strike plate 12A, between 0.125 and 0.5 inches thick.

As best shown in FIG. 6 , the inner mesh layer 15A also has a number ofintersecting walls 37A that define a plurality of open cells 39A betweenits inner and outer sides 35A, 33A. The walls 37A and cells 39A may bein a honeycomb pattern, grid pattern, or any other repeating ornon-repeating pattern. Any number of cells 39A of any size may be formedin the inner mesh layer. In one embodiment, the inner mesh layer 15A hasa cell density of approximately 12 cells per square inch, and each cellhas a volume of approximately 0.015 cubic inches. The inner mesh layer15A protects the wearer by adding a standoff distance of his or her bodyto the inner surface 20A of the strike plate 12A so that any highimpulse shock from an incoming projectile is insulated from the wearer.Further, the space within the inner mesh layer 15A captures any spallingor fragmentation penetrating through the inner surface 20A of the strikeplate 12A and/or captures any deformation of the strike plate 12Aitself.

As illustrated in FIGS. 5 & 6 , the inner mesh layer 15A may also haveaccess holes 41A along one or more of its edges through which excesspowder may drain after an additive manufacturing process has beencompleted. In embodiments which include expandable foam, these accessholes may also be used to inject the expandable foam as described inmore detail below.

The inner mesh layer 15A may be co-formed with the strike plate 12A viathe same additive manufacturing process or may be formed separately andadhered to the strike plate with adhesives or fasteners. For example,the inner mesh layer 15A may be formed first, and the strike plate 12Amay be formed on the outer surface 33A of the inner mesh layer 15A.Alternatively, the strike plate 12A may be formed first, and the innermesh layer 15A may be formed on the inner surface 20A of the strikeplate 12A. The other mesh layer 14A may be formed on the strike plate12A before or after formation of the inner mesh layer 15A. Further, theinner skin layer 17A may be formed first, then the inner mesh layer 15Amay be formed thereon. Alternatively, the inner skin layer 17A may beformed on the inner mesh layer 15A after the inner mesh layer 15A isformed on the strike plate 12A. The inner mesh layer 15A may be formedof the same metal matrix composite material as the strike plate 12A or adifferent material. The strike plate 12A, inner mesh layer 15A, innerskin layer 17A, the outer mesh layer 14A, and the outer skin layer 16Amay be formed any number of ways without departing from the scope of thepresent invention. For example, in some embodiments, the strike plate12A, the inner mesh layer 15A, and the inner skin layer 17A may beformed separately or at least partly together using additivemanufacturing and/or conventional methods. For example, the strike plate12A may be formed via conventional, non-additive manufacturing methods,and the inner mesh layer 15A/inner skin layer 17A and/or the outer meshlayer 14A/outer skin layer 16A may be formed on the strike plate 12A viaadditive manufacturing.

The inner skin layer 17A is positioned over the inner mesh layer 15A andhas an outer face 43A and an opposite inner face 45A. The inner skinlayer 17A may wrap around the edges of the inner mesh layer 15A so thatits outer face 43A encapsulates the open cells 39A of the mesh layer 15Abetween it and the strike plate 12A. The inner skin layer 17A may haveany thickness, and in one embodiment, is between 0.025 and 0.0625 inchesthick.

The inner skin layer 17A may be co-formed with the strike plate 12A viathe same additive manufacturing process or may be formed separately andadhered to the strike plate 12A. In some embodiments, the inner skinlayer 17A and the outer skin layer 16A may be formed together as asingle piece. The inner skin layer 17A may be formed of the same metalmatrix composite material as the strike plate 12A or a differentmaterial.

The open cells 39A in the inner mesh layer 15A entrap air. In otherembodiments, foam 19A at least partially fills the open cells 39A in theinner mesh layer 15A. The entrapped air or foam protect againstfragmentation. The foam 19A may be any expandable material. In oneembodiment, the foam is injected into the open cells 39A of the innermesh layer 15A via the access holes 41A. In other embodiments, the foam19A is added to the inner mesh layer 15A as the mesh layer isfabricated.

Exemplary methods of forming body armor plates such as the body armorplate 10A described above will now be described with reference to FIG. 7. The strike plate 12A, inner mesh layer 15A, inner skin layer 17A, theouter mesh layer 14A, and the outer skin layer 16A may be formed anynumber of ways without departing from the scope of the presentinvention. For example, in some embodiments, the strike plate 12A, theinner mesh layer 15A, and the inner skin layer 17A may be formedseparately or at least partly together using additive manufacturingand/or conventional methods. For example, the strike plate 12A may beformed via conventional, non-additive manufacturing methods, and theinner mesh layer 15A/inner skin layer 17A and/or the outer mesh layer14A/outer skin layer 16A may be formed on the strike plate 12A viaadditive manufacturing. Additionally, every layer that is additivelymanufactured together or additively manufactured in pieces may be formedon a conventional structure.

In one embodiment, the body armor plate 10A is fabricated with powderbed fusion additive manufacturing techniques comprising the followingsteps. The inner skin layer 17A may be formed by depositing metal matrixcomposite material on onto a form or other structure as shown in block196A. Alternatively, the inner skin layer 17A may be formed separatelyand glued on or otherwise attached over the inner mesh layer 15A. Theinner skin layer 17A is preferably formed so as to extend over the edgesof the inner mesh layer 15A to encapsulate the inner mesh layer 15Abetween the strike plate 12A and the inner skin layer 17A. In someembodiments, the inner skin layer 17A and the outer skin layer 16A maycomprise a single connected component. This step may comprise or beproceeded by the step of designing the shape and multi-curved profile ofthe inner skin layer 17A so it conforms to a particular wearer's torsoor other body part.

The inner mesh layer 15A may be formed by depositing a metal matrixcomposite material as shown in block 198A. In some embodiments, themetal matrix composite material is deposited onto the inner mesh layer15A. In embodiments in which the strike plate 12A is formed first, theinner mesh layer 15A may be formed on the strike plate 12A. The innermesh layer 15A may be formed so as to have a multi-curved profile, aninner face 35A, an outer face 33A, upper corner concave reliefs 24A,26A, and lower corner concave reliefs 28A, 30A as shown in FIG. 6 . Theinner mesh layer 15A may be formed so as to have a number ofintersecting walls 37A that define a number of open cells 39A. Theaccess holes 41A in the inner mesh layer 15A may also be formed in thisstep.

The strike plate 12A may be formed by depositing a metal matrixcomposite material onto the outer surface 33A of the inner mesh layer15A as shown in block 200A. The strike plate 12A may be formed so as tohave a multi-curved profile, an inner face 20A adjacent to the outerface 33A of the inner mesh layer 15A, an outer strike face 22A, uppercorner concave reliefs 24A, 26A, and lower corner concave reliefs 28A,30A as shown in FIG. 6 . In some embodiments, the strike plate 12A maybe formed first by depositing metal matrix composite material on onto aform or other structure, and the other layers 14A, 15A, 16A, 17A may beformed thereon. In other words, in some embodiments, this step 200A maychronologically precede steps 196A and 198A. And in some embodiments,the strike plate 12A may be formed using conventional methods and otherlayers formed thereon using additive manufacturing.

The outer mesh layer 14A is formed by depositing additional metal matrixcomposite material on the strike plate 12A as shown in block 202A.Alternatively, the outer mesh layer 14A may be formed separately fromthe strike plate 12A and subsequently glued or otherwise attached to thestrike plate 12A. The outer mesh layer 14A may be formed so as to havean inner side 32A positioned on the outer strike face 22A of the strikeplate 12A and an opposite outer side 34A. The outer mesh layer alsoincludes a number of intersecting walls 36A that define a number of opencells 38A. The access holes 40A in the mesh layer 14A may also be formedin this step.

The outer skin layer 16A is formed by depositing additional metal matrixcomposite material on the mesh layer 14A as shown in block 204A.Alternatively, the outer skin layer 16A may be formed separately andglued on otherwise attached over the mesh layer 14A. The outer skinlayer 16A is preferably formed so as to extend over the edges of themesh layer 14A to encapsulate the outer mesh layer 14A between thestrike plate 12A and the outer skin layer 16A.

During the formation of the layers 12A, 14A, 15A, 16A, 17A any unfusedmetal matrix powder may drain from the body armor plate via the accessholes 40A, 41A.

In embodiments of the body armor plate that include foam in the meshlayers 14A, 15A rather than entrapped air, expandable, buoyant, closedcell foam 18A, 19A is injected in the open cells 38A, 39A of the meshlayers 14A, 15A as depicted in block 206A. In some embodiments, othermaterials such as epoxies or polymers may be used instead of foam, andas mentioned above, in some embodiments, only air or other gas istrapped in the open cells 38A, 39A. The foam or other materials may beinjected into the open cells via the access holes 40A, 41A. The accessholes are then sealed with any suitable materials as depicted in block208A.

One or more of the fabricated body armor plates 10A is inserted in avest or other wearable item as depicted in block 210A. The plates 10Amay also be inserted in or attached to walls, door panels, and otherstructures or objects.

Forming some or all of the layers of the body armor plate 10A viaadditive manufacturing as described above permits the body armor platesto be sized and shaped to conform to a particular wearer's physique.Moreover, additive manufacturing permits the thicknesses of the strikeplate 12A and other layers to be selected to provide protection againstdifferent types and speeds of ballistic projectiles. Different portionsof each layer can also be formed in different thickness to provide extraprotection or extra mobility as needed. For example, portions of thelayers 12A, 14A, 15A, 16A, 17A configured to cover a wearer's heartmaybe relatively thicker for added protection whereas portions of thelayers configured to cover a wearer's hips may be relatively thinner toprovide better mobility.

Additional Considerations

In this description, references to “one embodiment,” “an embodiment,” or“embodiments” mean that the feature or features being referred to areincluded in at least one embodiment of the technology. Separatereferences to “one embodiment,” “an embodiment,” or “embodiments” inthis description do not necessarily refer to the same embodiment and arealso not mutually exclusive unless so stated and/or except as will bereadily apparent to those skilled in the art from the description. Forexample, a feature, structure, act, etc. described in one embodiment mayalso be included in other embodiments but is not necessarily included.Thus, the current technology can include a variety of combinationsand/or integrations of the embodiments described herein.

Although the present application sets forth a detailed description ofnumerous different embodiments, the legal scope of the description isdefined by the words of the claims set forth at the end of this patentand equivalents. The detailed description is to be construed asexemplary only and does not describe every possible embodiment sincedescribing every possible embodiment would be impractical. Numerousalternative embodiments may be implemented, using either currenttechnology or technology developed after the filing date of this patent,which would still fall within the scope of the claims.

Throughout this specification, plural instances may implementcomponents, operations, or structures described as a single instance.Although individual operations of one or more methods are illustratedand described as separate operations, one or more of the individualoperations may be performed concurrently, and nothing requires that theoperations be performed in the order illustrated. Structures andfunctionality presented as separate components in example configurationsmay be implemented as a combined structure or component. Similarly,structures and functionality presented as a single component may beimplemented as separate components. These and other variations,modifications, additions, and improvements fall within the scope of thesubject matter herein.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus.

The patent claims at the end of this patent application are not intendedto be construed under 35 U.S.C. § 112(f) unless traditionalmeans-plus-function language is expressly recited, such as “means for”or “step for” language being explicitly recited in the claim(s).

Although the invention has been described with reference to theembodiments illustrated in the attached drawing figures, it is notedthat equivalents may be employed and substitutions made herein withoutdeparting from the scope of the invention as recited in the claims.

Having thus described various embodiments of the invention, what isclaimed as new and desired to be protected by Letters Patent includesthe following:

The invention claimed is:
 1. A multi-layer armor plate comprising: astrike plate formed of metal matrix composite materials and comprisingan inner side and an outer side; an inner mesh layer positioned over theinner side of the strike plate, the inner mesh layer comprising aplurality of open cells; an outer mesh layer positioned over the outerside of the strike plate, the outer mesh layer comprising a number ofopen cells; an inner skin layer at least partially positioned over theinner mesh layer so as to encapsulate the open cells of the inner meshlayer between the strike plate and the inner skin layer; and an outerskin layer at least partially positioned over the inner mesh layer orouter mesh layer so as to encapsulate the open cells of the mesh layerbetween the strike plate and the outer skin layer.
 2. The armor plateset forth in claim 1, wherein the inner skin layer has a multi-curvedprofile for conforming to a wearer's torso, an inner side for at leastpartially covering the wearer's chest, upper corner concave reliefs foraccommodating the wearer's arms, and lower corner concave reliefs foraccommodating the wearer's hips and thighs.
 3. The armor plate set forthin claim 2, wherein the inner mesh layer is formed of metal and has anouter side positioned on the inner side of the strike plate, with theopen cells formed between the inner side and the outer side of the innermesh layer.
 4. The armor plate set forth in claim 3, wherein the opencells of the inner mesh layer entrap air.
 5. The armor plate set forthin claim 2, wherein the outer mesh layer is formed of metal and has aninner side positioned on the outer side of the strike plate, with theopen cells formed between the inner side and the outer side of the outermesh layer.
 6. The armor plate set forth in claim 1, wherein the metalmatrix composite materials comprise a metal matrix and a nanocellulosesupplement.
 7. The armor plate set forth in claim 1, wherein the innermesh layer has an inner side and the inner skin layer is formed of metaland has an outer face and an inner face, the outer face positioned overthe inner side of the inner mesh layer so as to encapsulate the opencells of the inner mesh layer between the strike plate and the innerskin layer.
 8. The armor plate set forth in claim 1, further comprisingexpandable, buoyant foam that at least partially fills the open cells ofthe inner mesh layer and the open cells of the outer mesh layer.
 9. Amulti-layer, wearable body armor plate comprising: a strike plate formedof metal matrix composite materials and having a multi-curved profilefor conforming to the wearer's torso, an inner face, an outer strikeface, upper corner concave reliefs for accommodating the wearer's arms,and lower corner concave reliefs for accommodating the wearer's hips andthighs; an outer mesh layer having an inner side positioned on the outerstrike face of the strike plate, an outer side, a number of open cellsformed between the inner side and the outer side, and edges between theinner side and the outer side; an inner mesh layer having an outer sidepositioned on the inner face of the strike plate, an inner side, anumber of open cells formed between the inner side and outer side, andedges between the inner side and the outer side; a metallic outer skinlayer positioned over the outer side and the edges of the outer meshlayer so as to encapsulate the open cells of the outer mesh layerbetween the strike plate and the outer skin layer; and a metallic innerskin layer positioned over the inner side and the edges of the innermesh layer so as to encapsulate the open cells of the inner mesh layerbetween the strike plate and the inner skin layer, the inner skin layerhaving an inner surface for at least partially covering the wearer'schest.
 10. The body armor plate set forth in claim 9, wherein the strikeplate is formed via additive manufacturing methods and has a thicknessof 0.125-0.5 inches.
 11. The body armor plate set forth in claim 9,wherein the metal matrix composite materials comprise a metal matrix anda nanocellulose supplement.
 12. The body armor plate set forth in claim9, wherein the inner mesh layer and the outer mesh layer are formed ofmetal and have a thickness of 0.125-0.5 inches.
 13. The body armor plateset forth in claim 12, wherein the open cells of the inner mesh layerand the open cells of the outer mesh layer entrap air.
 14. The bodyarmor plate set forth in claim 9, further comprising expandable, buoyantfoam that at least partially fills the open cells of the inner meshlayer and the open cells of the outer mesh layer.
 15. A method offorming a multi-layer, wearable body armor plate comprising: depositingmetal material via additive manufacturing to form a metallic inner skinlayer having an inner surface and an outer surface; depositing metalmaterial via additive manufacturing to form an inner mesh layer over theinner skin layer, the mesh layer having an inner side positioned on theouter surface of the inner skin layer, an outer side, and a number ofopen cells formed between the inner side and outer side; depositingmetal material via additive manufacturing to form a strike plate overthe inner mesh layer, the strike plate having an inner face positionedon the outer side of the inner mesh layer and an outer strike face;depositing metal material via additive manufacturing to form an outermesh layer over the strike plate, the outer mesh layer having an innerside positioned on the outer strike face of the strike plate, an outerside, a number of open cells formed between the inner side and outerside, and edges between the inner side and the outer side; anddepositing metal material via additive manufacturing to form a metallicouter skin layer over the outer side and the edges of the outer meshlayer so as to encapsulate the open cells of the mesh layer between thestrike plate and the outer skin layer.
 16. The method as set forth inclaim 15, wherein the metal material is a metal matrix compositematerial comprising a metal matrix and a nanocellulose supplement. 17.The method as set forth in claim 15, further comprising forming accessholes in the inner mesh layer and the outer mesh layer.
 18. The methodas set forth in claim 17, further comprising injecting expandable,buoyant foam in the open cells of the inner mesh layer and the outermesh layer.
 19. The method as set forth in claim 17, further comprisingsealing the access holes.
 20. The method as set forth in claim 15,further comprising forming the strike plate to have a thickness ofbetween 0.125-0.5 inches.